API RP 5UE (2002) - Recommended Practice for Ultrasonic Evaluation of Pipe Imperfections

Recommended Practice for Ultrasonic Evaluation of Pipe I m perfect i o n s

API RECOMMENDED PRACTICE 5UE FIRST EDITION, MARCH 2002

American Petroleum Institute

Helping You Get The Job Done Right?

COPYRIGHT American Petroleum InstituteLicensed by Information Handling ServicesCOPYRIGHT American Petroleum InstituteLicensed by Information Handling Services


Recommended Practice for Ultrasonic Evaluation of Pipe Imperfections

Upstream Segment

RECOMMENDED PRACTICE 5UE FIRST EDITION, MARCH 2002

American Petroleum Institute

Helping You Get The Job Done Right2


SPECIAL NOTES

API publications necessarily address problems of a general nature. With respect to partic- ular circumstances, local, state, and federal laws and regulations should be reviewed.

API is not undertaking to meet the duties of employers, manufacturers, or suppliers to warn and properly train and equip their employees, and others exposed, concerning health and safety risks and precautions, nor undertaking their obligations under local, state, or federal laws.

Information concerning safety and health risks and proper precautions with respect to par- ticular materials and conditions should be obtained from the employer, the manufacturer or supplier of that material, or the material safety data sheet.

Nothing contained in any API publication is to be construed as granting any right, by implication or otherwise, for the manufacture, sale, or use of any method, apparatus, or product covered by letters patent. Neither should anything contained in the publication be construed as insuring anyone against liability for infringement of letters patent.

Generally, API standards are reviewed and revised, r e a m e d , or withdrawn at least every five years. Sometimes a one-time extension of up to two years will be added to this review cycle. This publication will no longer be in effect five years after its publication date as an operative API standard or, where an extension has been granted, upon republication. Status of the publication can be ascertained from the API Upstream Segment [telephone (202) 682- 80001. A catalog of API publications and materials is published annually and updated quar- terly by API, 1220 L Street, N.W., Washington, D.C. 20005.

This document was produced under API standardization procedures that ensure appropriate notification and participation in the developmental process and is designated as an API standard. Questions concerning the interpretation of the content of this standard or com- ments and questions concerning the procedures under which this standard was developed should be directed in writing to the standardization manager, American Petroleum Institute, 1220 L Street, N.W., Washington, D.C. 20005. Requests for permission to reproduce or translate all or any part of the material published herein should also be addressed to the general manager.

API standards are published to facilitate the broad availability of proven, sound engineering and operating practices. These standards are not intended to obviate the need for applying sound engineering judgment regarding when and where these standards should be utilized. The formulation and publication of API standards is not intended in any way to inhibit anyone from using any other practices.

Any manufacturer marking equipment or materials in conformance with the marking requirements of an API standard is solely responsible for complying with all the applicable requirements of that standard. API does not represent, warrant, or guarantee that such products do in fact conform to the applicable API standard.

All rights reserved. No part of this work may be reproduced, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise,

without prior written permission from the publisher: Contact the Publishel; API Publishing Services, 1220 L Street, N. IT, Washington, D. C. 20005.

Copyright O 2002 American Petroleum Institute


FOREWORD

API publications may be used by anyone desiring to do so. Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any federal, state, or municipal regulation with which this publication may conñict.

Suggested revisions are invited and should be submitted to the standardization manager, American Petroleum Institute, 1220 L Street, N.W., Washington, D.C. 20005.

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CONTENTS

Page

1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Basis for Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Applicability of Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Factors that May Influence Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4.1 4.2 4.3

5 CERTIFICATION OF NONDESTRUCTIVE TESTING PERSONNEL . . . . . . . . . . 4

6 PROVE-UP TECHNIQUE DESCRIPTIONS ................................ 4 6.1 6.2

Amplitude Comparison Technique (ACT) .............................. 4 Amplitude Distance Differential Technique (ADDT) ...................... 4

7 GENERAL INSPECTION CRITERIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 7.1 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 7.2 Instrument and Transducer Equipment CalibratiodCertification . . . . . . . . . . . . . 4 7.3 Reference Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 7.4 Transducer, Angle Beam Wedge and Couplant Criteria .................... 5 7.5 InstrumentCriteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

8 STANDARDIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 8.2 Shear Wave Standardization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 8.3 Standardization Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

9 INSPECTION PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 9.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

10 ACCEPTANCE CRITERIA AND DISPOSITION ............................ 8

11 RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

APPENDIXA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 APPENDIXB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Figures 7.4.3.b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 8.2.2.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 A.l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 A.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 A.3.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A.3.b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 A.3.c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

V


A.3.2.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 B.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15


Recommended Practice for Ultrasonic Evaluation of Pipe Imperfections

1 Scope 1 . I This recommended practice (RP) describes procedures that may be used to “prove-up” the depth or size of imperfections. Included in this practice are the recommended procedures for ultrasonic prove-up inspection of new pipe using the Amplitude Comparison Technique (ACT) and the Amplitude Distance Differential Technique (ADDT) for 1) evaluation of surface breaking imperfections in the body of pipe and 2) surface breakmg and subsurface imperfections in the weld area of electric-resistance, electric-induction, or laser welded pipe. The applicable specification shall be the basis to determine the type and location of imperfection that is to be detected by inspection, and the acceptance/rejection criteria for the imperfection. For the purpose of this document, pipe is deked as including casing, plain-end casing liners, tubing, plain-end drill pipe, line pipe, coiled line pipe, pup joints, coupling stock, and connector material.

1.2 Prove-up inspection is a method to evaluate the radial depth of imperfections detected by automated inspection equipment or other nondestructive testing (NDT) technique@) to determine acceptance criteria compliance with the appropriate API specification.

1.3 The recommended prove-up practices established within this document are intended as a guide, and nothing in this guide should be interpreted to prohibit the agency or owner from supplementing the guide with other techniques or extending existing techniques.

1.4 This RP covers evaluation, a description of inspection methods, calibration and standardization procedures, and inspection personnel requirements for prove-up.

1.5 Appendix A of this document is provided as an over- view to inform the user of the basis for the techniques out- lined in this RP.

1.6 Appendix B of this document provides a procedure for determining if imperfections are surface breakmg and a formula for calculating the sound path distance for a circumferential or axial scan of a curved surface and a sample look-up table.

Spec 5D RP 5L8 Std 5T1

Drill Pipe Field Inspection of New Line Pipe Imperfection Termino logy

ASNT~ SNT-TC- 1A Personnel Qualijïcation and Certijïcation

in Nondestructive Testing

ASTM~ E 317 Standard Practice for Evaluating Perfor-

mance Characteristics of Ultrasonic Pulse-echo Testing Systems Without the Use of Electronic Measurement Instruments Standard Guide for Evaluating Character- istics of Ultrasonic Search Units

E 1065

3 Definitions The following terms are used frequently in the nondestruc-

tive testing of pipe:

3.1 A-scan: A method of data presentation utilizing a horizontal time-base that indicates distance or time and a vertical deflection from the base line that indicates amplitude.

3.2 active peak memory: The capability of an instrument to retain an A-scan presentation while allowing instrument controls to be functionally active.

3.3 agency: An entity contracted to inspect new pipe using the methods and criteria specified.

3.4 Amplitude Comparison Technique (ACT): An ultrasonic prove-up method comparing the reflected signals from a reference indicator of known radial depth and an imperfection.

3.5 Amplitude Distance Differential Technique (ADDT): An ultrasonic prove-up method comparing both the distance and amplitude at 50% peak amplitude levels from a reference indicator of known radial depth and an imperfection.

3.6 angle beam: An inspection method in which the angle of incidence or refraction is other than perpendicular to the surface of the test object being inspected. This includes the use of shear waves and longitudinal (compression) waves.

3.7 angle beam block: A specified type of reference standard used for the angle beam method.

2 References 2.1 This RP includes by reference, either in total or in part, the latest editions of the following API and industry standards, unless a specific edition is listed:

API RP 5A5

Spec 5CT

Field Inspection of New Casing, Tubing, and Plain-end Drill Pipe Casing and Tubing (US. Customary Units)

1

l h e r i c a n Society for Nondestructive Testing, Inc., 171 1 Arlington Lane, P.O. Box 28518, Columbus, Ohio 43228-0518. 2he r i can Society for Testing and Materials, 100 Barr Harbor Drive, West Conshohocken, Pennsylvania 19428-2959.


2 API RECOMMENDED PRACTICE 5UE

3.8 angle of incidence: The included angle between the beam axis of the incident wave and a line perpendicular to the surface at the point of incidence.

3.9 angle of refraction: The included angle between the beam axis of a refracted wave and a line perpendicular to the refraction interface.

3.1 O headquartered in Washington, D.C.

3.1 1 artificial discontinuity: See reference indicator.

3.12 ASNT: Abbreviation for American Society for Non- destructive Testing, headquartered in Columbus, Ohio.

3.13 ASTM: Abbreviation for American Society for Test- ing and Materials, headquartered in West Conshohocken, Pennsylvania.

3.14 axial scanning: Scanning for imperfections with a transverse orientation. The transducer is aligned with the longitudinal axis of the pipe.

3.15 calibration: The comparison of an instrument with, or the adjustment to, known reference@) often traceable to the National Institute of Standards and Technology (NIST).

3.1 6 certification: A written declaration stating compliance with stated criteria.

3.1 7 circumferential scanning: Scanning for imperfections with a longitudinal orientation. The transducer is aligned Perpendicular with the longitudinal axis of the pipe.

3.1 8 couplant: A material (usually a liquid) used between an ultrasonic transducer and the test specimen to conduct ultrasonic energy between them.

3.19 Differential Time of Flight: (T2 - TI) , time difference from the leading edge of signal envelope to the trailing edge of the signal envelope.

3.20 digital readout: Numeric display of ultrasonic data.

3.21 disposition: The action taken in conformance with the applicable API Specification with regard to an imperfection in a length of new pipe.

3.22 distance standardization: The adjustment of the A-scan display to accurately reflect known distances to specific positions on the time-base.

3.23 evaluation: The process of determining the sever- ity of an imperfection, which leads to determining whether the pipe is acceptable or rejectable under the appropriate specification.

3.24 frequency: Number of complete cycles of a wave motion per second of time. Unit of measure is called a hertz

API: Abbreviation for American Petroleum Institute,

(Hz).

3.25 FSH: Abbreviation for full screen height.

3.26 gain: The controlled adjustment of the amplified, displayed signal response in dB units.

3.27 gate: An electronic device for monitoring signals in a selected segment of the trace on an A-scan display.

3.28 gate start: The position along the A-scan display where the gate begins. The displayed value may be expressed in inches or microseconds.

3.29 gate width: The length of the gate along the A-scan display as measured from the gate start. The displayed value may be expressed in inches or microseconds.

3.30 IIW block (International Institute of Welding): See angle beam block.

3.31 imperfection: A discontinuity or irregularity in the product. For exact definitions and illustrations of specific imperfections, see API Std 5T1.

3.32 indication: A response from nondestructive inspection that requires interpretation in order to determine its sig- nificance.

3.33 instrument delay control: An electronic circuit used to adjust the start of the time-base. May also be referred to as the zero control.

3.34 instrument material velocity control: An electronic circuit used to adjust the length of the time-base relative to the velocity of the material being inspected. May also be referred to as the range or calibrate control.

3.35 inspection: The process of examining pipe for pos- sible defects or for deviation from established standards.

3.36 inspector: A person who is qualified and responsible for one or more of the inspections or tests specified in this document.

3.37 k factor: A derived factor for calculating depth when using the Amplitude Distance Differential Technique (ADDT).

3.38 longitudinal imperfection: An imperfection that has its principal direction or dimension approximately parallel to the longitudinal pipe axis.

3.39 marking: Assorted marks on tubular products, which includes inspection markings made with paint sticks and sten- cils, and ball-point paint tubes.

3.40 nondestructive testing (NDT): Inspection to detect defects or imperfections in materials, using techniques that do not damage or destroy the items being tested.

3.41 notch: See reference indicator.


RECOMMENDED PRACTICE FOR ULTRASONIC EVALUATION OF PIPE IMPERFECTIONS 3

3.42 oblique imperfection: An imperfection at an angle other than longitudinal or transverse to the axis of the pipe.

3.43 operator: The person present throughout the inspection or testing process who is responsible for the ultrasonic inspection unit, operates the controls, and observes the readout to detect imperfections.

3.44 owner: The entity who has ownership of the pipe at the time inspection is contracted, specifies and authorizes the type of inspection or testing to be conducted. The owner may be the purchaser.

3.45 parallax: Apparent displacement, or difference in the apparent position, of an object, caused by the actual change of the point of observation.

3.46 peak memory mode: An instrument capability that captures and stores the A-scan display.

3.47 pipe: Includes oil field casing, plain-end casing liners, tubing, plain-end drill pipe, line pipe, coiled line pipe, pup joints, coupling stock, and connector material.

3.48 plain-end: Pipe end without threads or tool joint.

3.49 planar: This term refers to an imperfection lying in one geometric plane that is normally parallel to, and within, the outer and inner surfaces.

3.50 prime pipe: Pipe meeting all of the specified inspection and testing requirements.

3.51 this Rp for measuring and evaluating imperfections.

3.52 pulse: A short wave train of mechanical vibrations.

3.53 pulse-echo method: An ultrasonic test method that both generates ultrasonic pulses and receives the return echo.

3.54 quality program: A documented system to ensure quality.

3.55 recommended practice (RP): A standard to facilitate the broad availability of proven sound engineering and operating practices.

3.56 reference indicator: Real or artificial discontinui- ties in a reference standard that provide reproducible sensitivity levels for inspection equipment. Artificial indicators may be holes, notches, grooves, or slots.

3.57 reference standard: A pipe, or pipe section, containing one or more reference indicators used as a base for comparison or for inspection equipment standardization.

3.58 reflection: The return of sound waves from surfaces.

prove-up: The ultrasonic processes described within

3.59 sensitivity: The size of the smallest imperfection detectable by a nondestructive test method with an acceptable signal-to-noise level.

3.60 shall: Used to indicate that a provision is mandatory.

3.61 should: Used to indicate that a provision is not mandatory but recommended as good practice.

3.62 signal: An electronic response of NDT equipment to an imperfection or defect.

3.63 signal envelope: The curve that encompasses suc- cessive return signals along the time-base on an A-scan display as an imperfection is scanned.

3.64 signal-to-noise ratio: The ratio of the signal from a significant imperfection or defect to signals generated from surface noise.

3.65 6 dB drop technique: An ultrasonic technique traditionally used as a means for the dimensional sizing of laminar imperfections in plate and for measuring the length of radial imperfections.

3.66 skip distance: In angle beam examination, the distance along the test surface, from sound entry point to the point at which the sound returns to the same surface. It can be considered the top surface distance of a complete vee path of sound in the test material.

3.67 skip position: The location on the A-scan display, along the time-base, relative to the skip distance for a given reflector.

3.68 sound path distance: The distance ultrasound travels from the entry point in the material to a given reflector.

3.69 standardization: The adjustment of instruments, to a known reference value.

3.70 standardization check: A check of the standardization adjustments to ensure that they remain correct.

3.71 that represents time or distance.

3.72 transducer: Electroacoustical device for converting electrical energy into acoustical energy and vice versa.

3.73 transverse imperfection: An imperfection that has its principal direction or dimension approximately perpendicular to the longitudinal pipe axis.

3.74 ultrasonic beam: A vibrating pulse wave train trav- eling through the material.

3.75 wedge: A device used to direct ultrasonic energy into a test object at an acute angle.

time-base: The horizontal line on the A-scan display



4 Application

4.1 BASIS FOR INSPECTION

The basis for prove-up inspection is the applicable API specification, or a supplemental specification or contract.

4.2 APPLICABILITY OF INSPECTION

The techniques contained in this RP are applicable to pipe regardless of size and type.

4.3 FACTORS THAT MAY INFLUENCE RESULTS

Every inspection and measurement process is characterized by an inherent variability of results. The results of the nondestructive inspections included in this Rp are dependent on the inherent variability of the techniques used and in part are attributable to the following factors:

4.3.1 Applicable API specifications permit options in the selection of the reference indicator.

4.3.2 Each manufacturer of nondestructive inspection equipment uses different mechanical and electronic designs.

4.3.3 Transducer frequency, diameter, focus, and angle beam wedge curvature.

4.3.4 Temperature.

4.3.5 Couplant.

4.3.6 Skill of inspector.

4.3.7 Surface condition variance between the reference standard and material to be inspected.

4.3.8 Imperfection type, shape, and orientation.

5 Certification of Nondestructive Testing Person ne1

As a minimum, ASNT Rp No. SNT-TC-1 A (or equivalent) shall be the basis of certification for ultrasonic testing personnel. Ultrasonic inspections shall be conducted by Level I, II, or III certified inspectors. Inspection personnel shall be trained and skilled in the techniques covered in this document and familiar with the applicable API pipe specifications.

6 Prove-up Technique Descriptions

6.1 AMPLITUDE COMPARISON TECHNIQUE (ACT)

The ACT is based on the premise that the amount of sound reflected from a material imperfection is proportional to the surface area of the imperfection. The peak signal amplitude from an imperfection is compared to that of a reference indicator of known size or depth.

Note: Empirical data has proven, when applying the ACT to the sizing of radial imperfections in tubular products, accuracy may vary due to several factors, which may include the material entry surface condition and the shape, orientation, and surface roughness of the imperfection.

6.2 Amplitude Distance Differential Technique (ADDT)

The ADDT is based on the premise that the radial depth of an imperfection affects both the amplitude of the received echo signal and the differential time of flight of the transmitted ultrasonic wave as it passes over the imperfection.

ADDT relates to the loss of signal amplitude, relative to time (distance), as the ultrasonic beam is moved over the imperfection. The amount of time (distance) to incur a 50% drop in amplitude of the returned signal is related to the depth of the imperfection. A discussion of the ADDT method is included in A. 1.

7 General Inspection Criteria 7.1 EQUIPMENT

7.1 . I Ultrasonic prove-up instrument.

7.1.2 Transducer and angle beam wedge with the appropriate angle of incidence depending on the pipe diameter, wall thickness, and the type of imperfection to be evaluated.

7.1.3 Reference standard.

7.2 INSTRUMENT AND TRANSDUCER EQUIPMENT CALIBRATIONKERTIFICATION

The instrument and transducer used to evaluate imperfections shall be verified in accordance with ASTM E 3 17 (instrument) and ASTM E 1065 (transducer) under the provisions of the manufacturer?s or agency?s documented quality program.

7.3 REFERENCE STANDARDS

A reference standard of the same specified diameter and thickness as the material being inspected shall be used. The material shall have ultrasonic velocity and attenuation proper- ties that are similar to those of the pipe being inspected and be free of imperfections.

The surface condition of the reference standard and the area being evaluated shall be similar. This shall be achieved by taking the reference standard and the area being evaluated from the same lot or by conditioning (e.g., bufñng) them to achieve a similar surface condition. The reference standard can be made from any convenient length or section of pipe.

7.3.1 Reference Indicators

All reference indicators shall be placed in an area of pipe where the wall thickness is within f 0.005 in. of the specified



wall thickness of the pipe to be inspected where practicable, or within f 0.005 in. of the typical wall thickness of the pipe to be inspected.

a. Notch dimensions and tolerances. 1. The minimum length shall be two times the specified transducer width (or diameter). 2. The depth shall be as per the applicable specification with a tolerance o f f 10% of the specified notch depth or f 0.002 in., whichever is geater. Notch depth shall be verified at a minimum of four points equally spaced where the notch is at full depth. All four points shall be within the above tolerances. The reported notch depth shall be the average of the four values. 3. The notch width shall not exceed 0.040 in. 4. The orientation of the notch shall be within 2" of the specified notch orientation relative to the pipe axis. 5. The radial orientation shall be such that the ultrasonic variance is no more than 1 dB from opposing sides at the center of the notch's length. This is determined by the formula:

dB = 20 log(A442)

where

Al = amplitude from side 1,

A2 = amplitude from side 2.

b. Through drilled hole dimension and tolerances. 1. The diameter shall be as per the specification and shall be based on the drill bit size in in. 2. The hole shall be drilled radially through the wall of the reference standard. 3. The radial orientation shall be such that the ultrasonic variance is no more than 1 dB from opposing sides of the drilled hole. This is determined by the formula:

dB = 20 log(A1/A2)

7.3.3 Identification

All permanent reference standards shall be identified. Such identity shall be used to trace recorded information with regard to reference indicators.

7.4 TRANSDUCER, ANGLE BEAM WEDGE AND COUPLANT CRITERIA

7.4.1 The transducer frequency range used shall be based on wall thickness as defined below:

a. A 2.0 - 5.0 MHz frequency transducer for specified wall thicknesses 0.250 in. or greater. b. A 3.5 MHz or higher frequency transducer for specified wall thicknesses less than 0.250 in.

7.4.2 Transducer width (or diameter) shall be l/4 to l/2 in.

7.4.3 Angle beam wedges shall be used to generate shear waves in the material to be inspected.

a. Angle beam wedges shall be either machine contoured or flat depending on the orientation of scanning and the pipe diameter. Angle beam wedges shall be machine contoured on pipe diameters less than 95/8 in. for longitudinal imperfections and on pipe diameters less than 5 in. for transverse imperfections. Flat angle beam wedges may be used for oblique imperfections. b. When contoured, the sound exit point shall be centered on the radius, see Figure 7.4.3 .b.

Contoured angle beam wedges must have their radius machined based on the specified maximum pipe diameter. The wedge radius must be centered based on the beam index point of the wedge relative to the perpendicular axis of the pipe. The radius of the wedge equals D,,/2.

7.4.4 Suitable couplant shall be used to eliminate air between the transducer and the angle beam wedge, and between the wedge and the pipe surface. The same type of couplant that is used for standardization shall be used during imperfection evaluation.

7.5 INSTRUMENT CRITERIA where

A l = amplitude from side 1,

A2 = amplitude from side 2.

7.3.2 Verification of Reference Indicators

Documentation of the reference standard shall contain data that verifies the conditions in 7.3.1 have been satisfied. Information recorded for each reference standard should include manufacturer, diameter, specified and actual wall thickness, dimensions of artificial reference indicators, and serial number.

7.5.1 General

a. The ultrasonic instrumentation shall be the pulse-echo type with an A-scan display capable of operating at frequen- cies specified in 7.4.1. b. Systems operated from line or external power sources should have voltage and frequency regulated to within manufacturer's specified requirements.

7.5.2 Optional

featuring active peak memory capabilities. For the ADDT, the instrument should be of the digital type



Dmax I

û = Pipe diameter ûmax = Maximum allowable pipe diameter

Figure 7.4.3.b

8 Standardization 8.1 GENERAL

8.1.1 When applicable, to eliminate parallax error during standardization and inspection, the A-scan display shall be viewed perpendicularly at all times.

8.1.2 The maximum amplitude shall be obtained from both sides at the center of the reference indicator in the reference standard with the higher amplitude being used as reference.

8.1.3 Non-linear reject control should be in the off position.

8.1.4 Selection of the reference indicator should be based on the following:

a. The specified notch should be used for standardization when the imperfection length is one half the specified transducer width (or diameter) or greater. b. The specified through drilled hole should be used for standardization when the imperfection length is less than one half the specified transducer width (or diameter). This is critical when a surface breaking imperfection has a shallow entry angle relative to the pipe surface or in the case of subsurface weld line imperfections.

8.2 SHEAR WAVE STANDARDIZATION

8.2.1 Amplitude Comparison Technique (ACT)

a. Veri@ that the angle of refraction is appropriate for the product to be evaluated using an angle beam block, IIW block, or other capable method.

b. Angle beam wedges with noticeable uneven wear at the bottom surface shall not be used. c. The instrument horizontal time-base or the digital readout shall be standardized for metal travel distance using a typical angle beam distance standardization block or other capable method. In order to enhance the accuracy of the horizontal distance measurement, the smallest range of the A-scan display should be used, but shall encompass the area of evaluation. d. Select the reference standard with the proper reference indicators as per 7.3. e. When distance standardization is performed on the flat surface of a reference block and evaluation is performed using a contoured angle beam wedge, the zero or delay control must be adjusted to compensate for the differences in the couplant/wedge transit time. This adjustment is made using the known sound path distance to the internal reference indicator at the l / 2 skip position. The sound path distance may be determined using the formulas in B.3. f. Locate the ID reference indicator and peak the signal at the l /2 skip position (AmJ.

For instances where the interface signal and the reference signal are not separate, use the 1 l /2 skip position and perform in accordance with item e above, using the 1 l / 2 skip distance.

Adjust the gain so that the signal is at 80% of full screen height (FSH) and note the reference gain value and location of the signal along the time-base. g. When applicable, locate the OD reference indicator and peak the signal at the 1 skip position (A,,).

Adjust the gain so that the signal is at 80% of FSH and note the reference gain value and location of the signal along the time-base.

8.2.2 Amplitude Distance Differential Technique (ADDT)

Note: 8.2.1 must be completed prior to standardizing in accordance with 8.2.2.

a. From the A,, position, move the transducer forward until the signal drops to l / 2 of A,,, and note the distance to this signal (Ti). Move the transducer back through the signal peak until the amplitude again drops to l /2 of A,,, and note the distance to this signal (T2) (see Figure 8.2.2.a). b. The calculated imperfection depth is the product of A,,, (Tz - Ti) and the k factor.

Calculate the k factor using the formula:

where

k = a derived factor for calculating depth,

d,. = depth of reference indicator,



A-Scan at A m a x

A-Scan at

2 A m a x

Figure 8.2.2.a

Amx = peak signal amplitude, 8.3.6 Prior to resuming operation after an equipment repair.

8.3.7 Whenever the transducer, cable, angle beam wedge or type of couplant is changed.

TI = time or distance to signal leading peak at l/2

amplitude,

T2 = time or distance to signal trailing peak at l/2 amplitude. 9 Inspection Procedures

c. To complete standardization, obtain values for A,,, ( T I ) and (T2) by repeating 8.2.2.a. Calculate the depth (d,) using the k factor derived in 8.2.2.b with the following formula:

9.1 GENERAL

If the imperfection is not accessible for mechanical measurement, then ultrasonic methods shall be used.

Standardization is acceptable when the calculated depth 9m2m1 General from at least tWO COnSeCUtiVe readings are within f 0.002 in. a. Standardize the shear wave unit as explained in Section 8. of the actual notch depth.

8.3 STANDARDIZATION CHECKS

b. Clean the surface of the pipe and apply a uniform amount of couplant to the area of the pipe to be inspected. c. When scanning to locate imperfections, add a minimum of four dB to the reference gain. d. The scanning direction should be perpendicular to the sus- pected imperfection orientation. The scanning speed should not exceed 5 in. per second. There should be an overlap

All pipe inspected between an unacceptable check and the most recent acceptable check shall be reinspected or rejected. Standardization checks shall be performed as follows:

8.3.1 At the beginning of each inspection shift. between scans.

a continuous operation.

8-33 After any Power intemption 01 change in Power SUP- ply (battery to charger). technique.

8.3.4 Whenever there is a change of operator (inspector).

8.3.5 Prior to equipment shutdown during a job.

8.3.2 At least once every 25 areas measured or inspected in 9.2.2 Surface or Subsurface Determination

a. When an imperfection is located, determine if the imperfection is surface breaking or subsurface using an acceptable

b. Techniques for makmg this determination should be based on the procedure located in Appendix B, 18.6.3 in API Rp 5A5, 16.5.2.1 in API Rp 5L8 or other accepted methods.



9.2.3 Evaluation Using Compression Wave

a. If the imperfection is determined to be surface breakmg in 9.2.2, the imperfection may be classified using the remaining wall value in accordance with 18.6.1 .fin API RP 5A5 for API Spec 5CT and Spec 5D product, as applicable. If the remaining wall value is less than the minimum wall thickness as defined in the applicable specification, the imperfection shall be classified as a defect. b. For surface breakmg linear imperfections, the radial depth of the imperfection may be used to classifj the imperfection by subtracting the remaining wall thickness (determined in 9.2.3.a) from the average wall thickness surrounding the imperfection. If the radial depth exceeds the depth tolerance as defined in the applicable specification, the imperfection shall be classified as a defect.

U I trason i cs

9.2.4 Imperfection Length Determination

The 6 dB drop technique should be used for locating the ends of the imperfection, when specified. The length of the imperfection is determined by measuring the distance between the ends per Appendix A (A. 1).

9.2.5 Evaluation Using ACT

a. For internal imperfections determined to be surface breaking in accordance with 9.2.2, the ACT may be applied. b. When an imperfection is located, that area shall be scanned rotating the transducer around the suspect area until peak amplitude is achieved for evaluation. c. Change the direction of the sound beam and observe the change in the displayed echo. (The echo from a smooth imperfecton is narrower than the echo from a rough imperfection. There is a greater loss of amplitude when the sound beam is moved around a linear imperfection than for a rounded imperfection.) d. Move the transducer back and forth, causing the beam to move up and down the imperfection depth. Watch the horizontal movement of the echoes left to right and vice versa along the A-scan display. (Greater movement of the echo indicates greater depth into the wall, assuming the depth in the radial direction. Horizontal movement that exceeds that of the reference indicator, even at low amplitude, indicates a imperfection that should be evaluated using ADDT or other capable method.) e. Return to position of peak signal amplitude. f. Adjust the gain so that the peak signal amplitude is at 80% of FSH and note the change in dB from the reference gain

value. A gain value less than the reference gain value indicates an amplitude greater than reference amplitude.

Note: The ADDT may be preferred in borderline situations. An example of a borderline situation is a shear wave indication with ACT results within 3 dB of the reference gain value. This is particu- larly true in the case of imperfections with irregular shapes or orien- tations other than perpendicular to the pipe surface.

9.2.6 Evaluation Using ADDT

a. The assumption is made that the axis of the beam is aligned with the edge of the imperfection when the amplitude of the imperfection reflection is half of its peak amplitude. At this point, half of the ultrasonic energy is being reflected back to transducer, while the other half continues through the material. b. Identifj the edges of the imperfection by manipulating the transducer back and forth across the imperfection. c. The depth of imperfection is calculated using the formula:

di = k(T2 - Ti) A

where

di = imperfection depth,

k = a derived factor for calculating depth,

T2 - Ti = differential time from leading edge of walk envelope to trailing edge of walk envelope,

A = amplitude.

1 O Acceptance Criteria and Disposition The applicable API specification, supplemental specifica-

tion, or contract shall constitute the basis for acceptance and disposition of the pipe inspected in accordance with this RP.

11 Records

following: 11.1 Records shall be maintained that include at least the

11 .I .I Pipe identification.

11 .I .2 Prove-up technique as identified in this RP.

11 .I .3 Prove-up reference standard dimensions and trace- ability.

11 .I .4 Prove-up results.

11 .I .5 Pipe disposition.


APPENDIX A

A.l Amplitude Distance Differential Technique

The ADDT employs a combination of amplitude comparison and 6 dB drop techniques to determine the radial depth of an imperfection. The technique is based on the premise that the radial depth of a imperfection affects both the amplitude of the received echo signal and the differential time of flight of the transmitted ultrasonic wave as it passes over the imperfection.

The 6 dB drop technique is traditionally used as a means for the dimensional sizing of laminar imperfections in plate and for measuring the length of radial imperfections. When sizing a lamination (Figure A.l), the maximum amplitude is noted when the transducer is in position A. The transducer is then advanced until the peak signal amplitude decreases by 50%, position B, where the center of the transducer is positioned directly over the edge of the imperfection. The surface of the material is marked at the center of the transducer and the process is repeated in the opposite direction, and in the other dimension, thus mapping the size and location of the imperfection. This is a relatively simple but accurate technique for sizing imperfections. This technique is only accurate, how-

A

ever, when the imperfection dimension being measured is greater than the effective width of the ultrasonic beam.

When applying ADDT, a derived factor for calculating depth known as the k factor must be applied to compensate for combined test variables including, but not limited to, beam angle, effective beam width, pipe diameter and wall thickness, and imperfection position.

The ADDT can be performed using any basic ultrasonic imperfection detector, but is simpler, more accurate and much less time consuming when using a digital instrument featuring active peak memory capability.

Standardization must be performed using a reference indicator such as a notch of known depth or a through drilled hole. When using a notch, the actual notch depth is used as the basis for standardization, while the material wall thickness is the basis for standardization when using a through drilled hole. The following paragraphs explain typical standardization and imperfection measurement processes for both ultrasonic instruments, with and without active peak memory capability.

B - I I '

I I ' I I ' I I \ I I ' I I I I I ' I I I I I ' I I I I I I , I I I 1 I I I \ I

I I I I

1 I \ r , 1 , 1 1 Lamination

A B

O 1 2 3 4 5 6 7 8 9 10 O 1 2 3 4 5 6 7 8 9 10

Figure A. l

9



A.2 Ultrasonic Instruments without Active Peak Memory Capability

The instrument horizontal time-base or digital readout must ñrst be standardized for metal travel distance using an Angle Beam block, IIW block or other capable method. To maximize resolution, the range of the A-scan display should be minimal, but sufficient to encompass the complete signal envelope.

When a contoured angle beam wedge is used during standardization on the (curved) reference standard an adjustment to the zero or delay control must be made while the angle beam wedge is on the pipe surface to compensate for the difference in couplant thickness.

As shown in Figure A.2, with the reference signal at peak amplitude, the gain is adjusted to achieve 80% FSH (A,, =

0.80). The transducer is then moved forward until the signal drops to l/2 of Amx, and the distance to this signal (Ti) is noted. The transducer is then moved back through the signal peak until the amplitude again drops to l/2 of Amx, and the distance to this signal (T2) is noted. The calculated imperfection depth is the product of A,,, (T2 - Ti) and the k factor. The k factor is derived using the formula:

where

k = k factor, a derived factor for calculating depth,


Amx = peak signal amplitude,

Ti = time or distance to signal leading peak at l/2

amplitude,

T2 = time or distance to signal trailing peak at l/2

amplitude.

The establishment of the reference gain value and the k factor constitutes standardization of the instrument to the material being inspected and the specific transducer being utilized. The gain value used to establish standardization must remain constant during imperfection depth measurement.

When measuring the radial depth of an imperfection, the A,,, Ti and T2 are determined by maximizing the imperfection signal and manipulating the transducer forward and back in the same manner as was used during standardization.

The depth of an imperfection is calculated using the formula:

di = Amx( 7'2 - T1)k

A-Scan at

A max

A-Scan at A m a x -

2

O 1 2 3 4 5 6 7 8 9 10

Figure 14.2



where



Ti = time or distance to signal leading peak at l12

amplitude,

T2 = time or distance to signal trailing peak at l12

amplitude,

k = k factor, a derived factor for calculating depth.

A.2.1 STANDARDIZATION EXAMPLE

Determine the k factor where:

d,. = 0.032 in.,

Amx = 80%FSH,

Ti = 0.675 in.,

T2 = 0.740 in.

k = 0.032 I 0.80(0.740 - 0.675)

k = 0.032 10.80 x 0.065

k = 0.032 10.052

k = 0.615 or 0.62

A.2.2 IMPERFECTION MEASUREMENT EXAMPLE

Amx = 84%FSH

Ti = 0.588"

T2 = 0.655"

k = 0.62

di = 0.84(0.655 - 0.588)0.62

di = 0.84 x 0.067 x 0.62

di = 0.056 x 0.62

di = 0.035

A.3 Ultrasonic Instruments with Active Peak Memory Capability

When using digital ultrasonic instrumentation with active peak memory capability, it is not necessary to calculate the k factor. The gate is used to measure T2 - Ti by plotting the signal envelope of the imperfection while in the peak memory mode and adjusting the gate such that it encompasses the displayed signal envelope at 50% of Amp When applied as such, the gate width value becomes (T2 - Ti). This value can be manipulated by adjusting the instrument material velocity control (the resultant value may not be the actual velocity of the material being inspected). It should be noted that most digital ultrasonic instruments have a minimum velocity value of 0.025 in. per microsecond or more, which in many cases is

A-Scan at

A max

A-Scan at

'12 A m a x

--..- A max Level

- - /2 A max Level

Figure A.3.a



Figure A.3.b

not sufficiently low. For this reason, it may be necessary to use l12 or some other fraction of A,, when formulating the equations.

The signal envelope of the A-Scan (Figure A.3.a) is cap- tured by scanning across an imperfection as shown in Figure A.3.b with the instrument peak memory mode enabled.

Standardization is performed by scanning over the reference reflector while in the instrument peak memory mode, adjusting the gate level to 50% ofA,,, and adjusting the gate start and width to span the width of the signal envelope as shown in Figure A.3.c. The following equation is then used to calculate the gate width value required for standardization:

GW = d,. I (A,, I 2)

where

GW = gate width,


Amx = peak signal amplitude.

The instrument material velocity control is then adjusted until the appropriate gate width value is achieved. The establishment of the reference gain value and the instrument material velocity control value, both of which are constants, constitutes standardization of the instrument to the material being inspected and the specific transducer being utilized. The gain value used to establish standardization must remain constant during imperfection depth measurement.

Radial depth measurement is performed by plotting the signal envelope and adjusting the gate as illustrated in Figure A.3.c. The radial depth is calculated using the equation:

di = (Amx I 2)G W

where



GW = gate width.



A-Scan at

A max

A-Scan at

'12 Amax

88%FSH --

44% FSH -I

Peak Memory

Envelope of A-Scan

rGate Width ' I

1 2 3 4 5 6 7 8 9 10

Figure A.3.c

"'A max Level

/2 A Level

Gate Width

0.073

I -..-- A,,, Level

Level Amax -..- 2

Figure 14.3.2



A.3.1 STANDARDIZATION EXAMPLE

Determine gate width value:

where

d,. = 0.028 in.,

Amx = 830%FSH,

Amx/2 = 40% FSH,

GW = 0.028 l (O.80 12),

GW = 0.02810.40,

GW = 0.070.

A.3.2 IMPERFECTION MEASUREMENT EXAMPLE (FIGURE A.3.2)

A m X = 88%FSH,

Amx12 = 44%FSH,

GW = 0.073in.

di = (0.88 12) x 0.073 di = 0.44 x 0.073 di = 0.032

Because of its relatively time consuming nature, the ADDT is recommended for use in determining the final disposition of imperfections whose depth cannot be determined using other methods, and when the ACT results are within 3 dB of the reference amplitude. The ADDT method is also recommended for use when the differential time of fiight measwe- ment from the imperfection exceeds that of the reference indicator regardless of amplitude.


APPENDIX B

B.l Surface or Subsurface Determination Since the API specifications referenced throughout this Rp

only require surface breaking defects to be located and evaluated, except for the weld area of welded product, part of any evaluation process should include a means of determining if the imperfection being evaluated is surface breakmg or subsurface. Subsurface imperfections, except those in the weld area of welded product, do not require evaluation.

The following procedure provides one technique for determining if the imperfection to be evaluated breaks the internal surface of the pipe. This procedure is based on a known sound path distance, at a given refracted angle, to the internal surface and a corresponding wall thickness value that corre- late within a given tolerance.

B.2 When an imperfection is located, scribe a line on the surface of the pipe directly in front of the wedge (with the indication peaked-position A in Figure B.2).

B.2.1 Repeat B.2 from the opposite side ofthe imperfection.

B.2.2 Determine the average wall thickness surrounding the indication (position B in Figure B.2).

B.2.3 After peaking up on the indication using the shear wave method, adjust the gain such that the maximized signal is approximately 80% FSH. Note the gain value and the

sound path distance as indicated on the A-scan display or the digital readout.

Note: Most analog and some digital ultrasonic instruments that provide numerical sound path distance base the “depth” calculation on flat plate. This calculation will be correct during an axial scan but due to the pipe curvature, the calculation will not be correct during a circumferential scan; however, some digital instruments contain curvature correction software and thus provide a correct “depth” calculation.

The formula in B.3 may be used to develop a look-up reference table from which the correct depth value may be obtained based on a given wall thickness when using ultrasonic instruments without curvature correction software or a digital readout.

B.2.4 For digital instruments with curvature correction software or for any instrument with a digital readout when performing an axial scan, adjust the instrument controls to display the “depth” mode on the digital readout and note the reading.

B.2.5 For instruments without a digital readout, refer to a look up table (based on the formulas in B.3) and note the wall thickness value corresponding to the circumferential sound path distance noted in B.2.3.

COMPRESSION WAVE TRANSDUCER

SHEAR WAVE TRANSDUCER

Figure B.2

15



B.2.6 Repeat the applicable portions of B.2.3 through B.2.5 from both sides of the indication.

B.2.7 Ifthe actual wall thickness differs by 0.010 in. or less from the wall thickness value@) noted in either B.2.4 or B.2.5, the indication may be considered to be surface breaking.

B.2.8 If the actual wall thickness differs by more than 0.010 in. and by less than 0.020 in. from the wall thickness value(s) noted in either B.2.4 or B.2.5, the indication should be visually inspected with a borescope to determine if the imperfection is surface b r e h g . Magnetic particles may be used in conjunction with the borescope to enhance detection.

B.2.9 If the imperfection is determined to be surface breaking, proceed in accordance with 9.2.3.

B.3 Sound Path Formulas Circumferential Scan:

a2 = R22 +Rl2-2R2RIco~[sin?((R2/RI)sinp)- p]

Axial Scan:

a = t/(cosD)

where

a = 1 leg of the sound path (l/2 skip),

R2 = Radius2 = O.D./2,

R1 = Radius1 =R2- t,

t = wall thickness,

p = refracted angle.

B.4 Sample Look-up Table The above formula may be used to develop a Look-up

Table by pipe size and corresponding wall thickness. Below is such an example:

Ultrasonic Sound Path Distances in Inches4.D.: 9.625 Refracted Angle: 45":


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